Patent EA-000720-B1 (EA)
Title: Aluminum promoted hydrogeneration of alkylation sludge for aluminum chloride recovery
Inventor: DOANE ELLIOTT P
IPC: C01F7/56
Filed: 1997-12-20
Abstract: 1. A process for the recovery of aluminum chloride from a sludge complex resulting from an aluminum chloride-catalyzed alkylation reaction comprising forming a mixture of the sludge complex and catalytic aluminum; and reacting the complex and catalytic aluminum in the presence of hydrogen to form aluminum chloride. 2. The process of claim 1 wherein hydrogen is provided in the gaseous state at an excessive pressure of from about 500 psig (35 kg/sm<2> =34 atm) to about 1500 psig. (105 kg/sm<2> =102 atm) 3. The process of claim 2 wherein hydrogen is provided in the gaseous state at an excessive pressure  of from about 1000 psig (70 kg/sm<2> =68 atm) to about 1500 psig. (105 kg/sm<2> =102 atm). 4. The process of claim 3 wherein hydrogen is provided in the gaseous state at an excessive pressure of about 1500 psig. (105 kg/sm<2> =102 atm). 5. The process of claim 1 wherein the reaction step is carried out at a temperature of from about 125 to about 200 degree C. 6. The process of claim 5 wherein the reaction temperature is from about 140 to about 180 degree C. 7. The process of claim 6 wherein the reaction temperature is about 150 degree C. 8. The process of claim 1 wherein the reaction step is carried out for a time of from about 2 to about 4 hours. 9. The process of claim 8 wherein the reaction step is carried out for a time of about 3 hours. 10. The process of claim 1 wherein the aluminum chloride so formed is capable of being removed from the reaction mixture. 11. The process of claim 1 wherein the aluminum chloride is removed by dissolving in isobutane. 12. The process of claim 10 wherein the aluminum chloride so formed is removed by allowing said reaction mixture to cool and the aluminum chloride to precipitate. 13. The process of claim 10 including the step of recovering the aluminum chloride so removed. 14. The process of claim 1 performed as a batch process. 15. The process of claim 14 wherein the sludge complex and catalytic aluminum are mixed in a ratio of from about 6:1 to about 7:1. 16. The process of claim 15 wherein the sludge complex and catalytic aluminum are mixed in a ratio of about 6:1. 17. The process of claim 1 performed as a continuous process. 18. The process of claim 1 performed as a batchwise-continuous process. 19. The process of claim 1 wherein said catalytic aluminum is in powder form. 20. The process of claim 1 wherein said catalytic aluminum is in gauze form. 21. The process of claim 1, wherein said catalytic aluminum is at least 99% pure aluminum. 22. The process of claim 1 wherein said sludge complex contains aluminum chloride and olefinic hydrocarbon compounds. 23. The process of claim 1 wherein said sludge complex results from the alkylation of olefins using a homogeneous aluminum chloride-based catalyst. 24. The process of claim 23 wherein said homogeneous aluminum chloride-based catalyst comprises about 46 weight percent bound-hydrocarbon and about 54 weight percent bound-aluminum chloride. 25. The process of claim 1 wherein the processing rate is from about 2 to about 3 weight sludge complex / hour / weight of catalytic aluminum. 26. The process of claim 1 wherein the reactants are constantly agitated. 27. The process of claim 5 wherein the reaction mixture is constantly agitated during the time it is being heated. 28. The process of claim 17 including the steps of: passing alkylate, isobutane, and sludge complex from an alkylation zone to a settling tank and allowing the sludge complex to settle from the alkylate; continuously transferring said sludge complex from said settling tank to a hydrogenation zone; contacting said sludge complex with catalytic aluminum in the presence of hydrogen gas and isobutane; forming aluminum chloride; continuously dissolving said aluminum chloride in said isobutane; and discharging the aluminum chloride-isobutane solution from said hydrogenation zone. 29. The process of claim 18 including the steps of: passing alkylate, isobutane, and sludge complex from an alkylation zone to a settling tank and allowing the sludge complex to settle from the alkylate; transferring said sludge complex from said settling tank to a hydrogenation zone at set intervals; contacting said sludge complex with catalytic aluminum in the presence of hydrogen gas and isobutane; forming aluminum chloride;  continuously dissolving said aluminum chloride in said isobutane; and discharging the aluminum chloride-isobutane solution from said hydrogenation zone. 30. The process of claim 28 wherein said aluminum chloride-isobutane solution is recycled to said alkylation zone. 31. The process of claim 29 wherein said aluminum chloride-isobutane solution is recycled to said alkylation zone. 32. The process of claim 28 wherein said catalytic aluminum is in a mesh form. 33. The process of claim 29 wherein said catalytic aluminum is in a mesh form. 34. The process of claim 28 including constantly agitating the reactants and reaction products in the hydrogenation zone. 35. The process of claim 29 including constantly agitating the reactants and reaction products in the hydrogenation zone.